Electromagnetic forming of metallic glasses using a capacitive discharge and magnetic field

ABSTRACT

An apparatus and method of uniformly heating, rheologically softening, and thermoplastically forming metallic glasses rapidly into a net shape using a rapid capacitor discharge forming (RCDF) tool in combination with an electromagnetic force generated by the interaction of the applied current with a transverse magnetic field. The RCDF method utilizes the discharge of electrical energy stored in a capacitor to uniformly and rapidly heat a sample or charge of metallic glass alloy to a predetermined “process temperature” between the glass transition temperature of the amorphous metal and the equilibrium melting point of the alloy in a time scale of several milliseconds or less, at which point the interaction between the electric field and the magnetic field generates a force capable of shaping the heated sample into a high quality amorphous bulk article via any number of techniques including, for example, injection molding, dynamic forging, stamp forging, and blow molding in a time scale of less than one second.

CROSS-REFERENCE TO RELATED APPLICATIONS

The current application claims priority to U.S. Provisional ApplicationNo. 61/322,209, filed Apr. 8, 2010, the disclosure of which isincorporated herein by reference.

FIELD OF THE INVENTION

This invention relates generally to a novel method of forming metallicglass; and more particularly to a process for forming metallic glassusing rapid capacitor discharge heating and a magnetic field to apply anelectromagnetic forming force.

BACKGROUND OF THE INVENTION

Amorphous materials are a new class of engineering material, which havea unique combination of high strength, elasticity, corrosion resistanceand processability from the molten state. Amorphous materials differfrom conventional crystalline alloys in that their atomic structurelacks the typical long-range ordered patterns of the atomic structure ofconventional crystalline alloys. Amorphous materials are generallyprocessed and formed by cooling a molten alloy from above the meltingtemperature of the crystalline phase (or the thermodynamic meltingtemperature) to below the “glass transition temperature” of theamorphous phase at “sufficiently fast” cooling rates, such that thenucleation and growth of alloy crystals is avoided. As such, theprocessing methods for amorphous alloys have always been concerned withquantifying the “sufficiently fast cooling rate”, which is also referredto as “critical cooling rate”, to ensure formation of the amorphousphase.

The “critical cooling rates” for early amorphous materials wereextremely high, on the order of 10⁶° C./sec. As such, conventionalcasting processes were not suitable for such high cooling rates, andspecial casting processes such as melt spinning and planar flow castingwere developed. Due to the crystallization kinetics of those earlyalloys being substantially fast, extremely short time (on the order of10⁻³ seconds or less) for heat extraction from the molten alloy wererequired to bypass crystallization, and thus early amorphous alloys werealso limited in size in at least one dimension. For example, only verythin foils and ribbons (order of 25 microns in thickness) weresuccessfully produced using these conventional techniques. Because thecritical cooling rate requirements for these amorphous alloys severelylimited the size of parts made from amorphous alloys, the use of earlyamorphous alloys as bulk objects and articles was limited.

Over the years it was determined that the “critical cooling rate”depends strongly on the chemical composition of amorphous alloys.Accordingly, a great deal of research was focused on developing newalloy compositions with much lower critical cooling rates. Examples ofthese alloys are given in U.S. Pat. Nos. 5,288,344; 5,368,659;5,618,359; and 5,735,975, each of which is incorporated herein byreference. These amorphous alloy systems, also called bulk-metallicglasses or BMGs, are characterized by critical cooling rates as low as afew ° C./second, which allows the processing and forming of much largerbulk amorphous phase objects than were previously achievable.

With the availability of low “critical cooling rate” BMGs, it has becomepossible to apply conventional casting processes to form bulk articleshaving an amorphous phase. Over the past several years, a number ofcompanies, including LiquidMetal Technologies, Inc. have undertaken aneffort to develop commercial manufacturing technologies for theproduction of net shape metallic parts fabricated from BMGs. Forexample, manufacturing methods such as permanent mold metal die-castingand injection casting into heated molds are currently being used tofabricate commercial hardware and components such as electronic casingsfor standard consumer electronic devices (e.g., cell phones and handheldwireless devices), hinges, fasteners, medical instruments and other highvalue added products. However, even though bulk-solidifying amorphousalloys provide some remedy to the fundamental deficiencies ofsolidification casting, and particularly to the die-casting andpermanent mold casting processes, as discussed above, there are stillissues which need to be addressed. First and foremost, there is a needto make these bulk objects from a broader range of alloy compositions.For example, presently available BMGs with large critical castingdimensions capable of making large bulk amorphous objects are limited toa few groups of alloy compositions based on a very narrow selection ofmetals, including Zr-based alloys with additions of Ti, Ni, Cu, Al andBe and Pd-based alloys with additions of Ni, Cu, and P, which are notnecessarily optimized from either an engineering or cost perspective.

In addition, the current processing technology requires a great deal ofexpensive machinery to ensure appropriate processing conditions arecreated. For example, most shaping processes require a high vacuum orcontrolled inert gas environment, induction melting of material in acrucible, pouring of metal to a shot sleeve, and pneumatic injectionthrough a shot sleeve into gating and cavities of a rather elaboratemold assembly. These modified die-casting machines can cost severalhundreds of thousands of dollars per machine. Moreover, because heatinga BMG has to date been accomplished via these traditional, slow thermalprocesses, the prior art of processing and forming bulk-solidifyingamorphous alloys has always been focused on cooling the molten alloyfrom above the thermodynamic melting temperature to below the glasstransition temperature. This cooling has either been realized using asingle-step monotonous cooling operation or a multi-step process. Forexample, metallic molds (made of copper, steel, tungsten, molybdenum,composites thereof, or other high conductivity materials) at ambienttemperatures are utilized to facilitate and expedite heat extractionfrom the molten alloy. Because the “critical casting dimension” iscorrelated to the critical cooling rate, these conventional processesare not suitable for forming larger bulk objects and articles of abroader range of bulk-solidifying amorphous alloys. In addition, it isoften necessary to inject the molten alloy into the dies at high-speed,and under high-pressure, to ensure sufficient alloy material isintroduced into the die prior to the solidification of the alloy,particularly in the manufacture of complex and high-precision parts.Because the metal is fed into the die under high pressure and at highvelocities, such as in high-pressure die-casting operation, the flow ofthe molten metal becomes prone to Rayleigh-Taylor instability. This flowinstability is characterized by a high Weber number, and is associatedwith the break-up of the flow front causing the formation of protrudedseams and cells, which appear as cosmetic and structural micro-defectsin cast parts. Also, there is a tendency to form a shrinkage cavity orporosity along the centerline of the die-casting mold when unvitrifiedliquid is trapped inside a solid shell of vitrified metal.

Attempts to remedy the problems associated with rapidly cooling thematerial from above the equilibrium melting point to below the glasstransition were mostly focused on utilizing the kinetic stability andviscous flow characteristics of the supercooled liquid. Methods havebeen proposed that involve heating glassy feedstock above the glasstransition where the glass relaxes to a viscous supercooled liquid,applying pressure to form the supercooled liquid, and subsequentlycooling to below glass transition prior to crystallizing. Theseattractive methods are essentially very similar to those used to processplastics. In contrast to plastics however, which remain stable againstcrystallization above the softening transition for extremely longperiods of time, metallic supercooled liquids crystallize rather rapidlyonce relaxed at the glass transition. Consequently, the temperaturerange over which metallic glasses are stable against crystallizationwhen heated at conventional heating rates (20° C./min) are rather small(50-100° C. above glass transition), and the liquid viscosity withinthat range is rather high (10⁹-10⁷ Pa s). Owing to these highviscosities, the pressures required to form these liquids into desirableshapes are enormous, and for many metallic glass alloys could exceed thepressures attainable by conventional high strength tooling (<1 GPa).Metallic glass alloys have recently been developed that are stableagainst crystallization when heated at conventional heating rates up toconsiderably high temperatures (165° C. above glass transition).Examples of these alloys are given in U.S. Pat. Appl. 20080135138 andarticles to G. Duan et al. (Advanced Materials, 19 (2007) 4272) and A.Wiest (Act Materialia, 56 (2008) 2525-2630), each of which isincorporated herein by reference. Owing to their high stability againstcrystallization, process viscosities as low as 10⁵ Pa-s becomeaccessible, which suggests that these alloys are more suitable forprocessing in the supercooled liquid state than traditional metallicglasses. These viscosities however are still substantially higher thanthe processing viscosities of plastics, which typically range between 10and 1000 Pa-s. In order to attain such low viscosities, the metallicglass alloy should either exhibit an even higher stability againstcrystallization when heated by conventional heating, or be heated at anunconventionally high heating rate which would extend the temperaturerange of stability and lower the process viscosity to values typical ofthose used in processing thermoplastics.

A few attempts have been made to create a method of instantaneouslyheating a BMG up to a temperature sufficient for shaping, therebyavoiding many of the problems discussed above and simultaneouslyexpanding the types of amorphous materials that can be shaped. Forexample, U.S. Pat. Nos. 4,115,682 and 5,005,456 and articles to A. R.Yavari (Materials Research Society Symposium Proceedings, 644 (2001)L12-20-1, Materials Science & Engineering A, 375-377 (2004) 227-234; andApplied Physics Letters, 81(9) (2002) 1606-1608), the disclosures ofeach of which are incorporated herein by reference, all take advantageof the unique conductive properties of amorphous materials toinstantaneously heat the materials to a shaping temperature using Jouleheating. However, thus far these techniques have focused on localizedheating of BMG samples to allow for only localized forming, such as thejoining (i.e., spot welding) of such pieces, or the formation of surfacefeatures. None of these prior art methods teach how to uniformly heatthe entire BMG specimen volume in order to be able to perform globalforming. Instead, all those prior art methods anticipate temperaturegradients during heating, and discuss how these gradients could affectlocal forming. For instance, Yavari et al. (Materials Research SocietySymposium Proceedings, 644 (2001) L12-20-1) write: “The externalsurfaces of the BMG specimen being shaped, whether in contact with theelectrodes or with the ambient (inert) gas in the shaping chamber, willbe slightly cooler than the inside as the heat generated by the currentdissipates out of the sample by conduction, convection or radiation. Onthe other hand, the outer surfaces of samples heated by conduction,convection or radiation are slightly hotter than the inside. This is animportant advantage for the present method as crystallization and oroxidation of metallic glasses often begin first on outer surfaces andinterfaces and if they are slightly below the temperature of the bulk,such undesirable surface crystal formation may be more easily avoided.”

Another drawback of the limited stability of BMGs againstcrystallization above the glass transition is the inability to measurethermodynamic and transport properties, such as heat capacity andviscosity, over the entire range of temperatures of the metastablesupercooled liquid. Typical measurement instruments such as DifferentialScanning calorimeters, Thermo-Mechanical Analyzers, and CoquetteViscometers rely on conventional heating instrumentation, such aselectric and induction heaters, and are thus capable of attaining sampleheating rates that are considered conventional (typically <100° C./min).As discuss above, metallic supercooled liquids can be stable againstcrystallization over a limited temperature range when heated at aconventional heating rate, and thus the measureable thermodynamic andtransport properties are limited to within the accessible temperaturerange. Consequently, unlike polymer and organic liquids which are verystable against crystallization and their thermodynamic and transportproperties are measureable throughout the entire range of metastability,the properties of metallic supercooled liquids are only measureable towithin narrow temperature ranges just above the glass transition andjust below the melting point.

Recently, a method has been developed which overcomes many of thelimitations of these conventional methods by uniformly heating,rheologically softening, and thermoplastically forming metallic glassesrapidly into a net shape using a rapid capacitor discharge forming(RCDF) tool. (See, e.g., U.S. Pat. Pub. No. US-2009-0236017-A1, thedisclosure of which is incorporated herein by reference.) The RCDFmethod utilizes the discharge of electrical energy stored in a capacitorto uniformly and rapidly heat a sample or charge of metallic glass alloyto a predetermined “process temperature” between the glass transitiontemperature of the amorphous material and the equilibrium melting pointof the alloy in a time scale of several milliseconds or less. However,in this method the application of force to shape the heated sample intohigh quality amorphous bulk articles is done through conventionaltechniques, which are not optimal.

Accordingly, a need exists to find a novel approach to shape the heatedBMG specimen that exploits the electric field generated in theinstantaneous RCDF heating method.

SUMMARY OF THE INVENTION

A method of forming metallic glass, sheets, tubes, or rods is disclosedwhich utilizes an electromagnetic forming force to shape a metallicglass charge in the form of a sheet, tube, or rod of essentially uniformcross section.

In one embodiment, the invention is directed to a method of rapidlyheating and shaping an amorphous material using a rapid capacitordischarge and electromagnetic force, and includes:

-   -   providing at least one sample of amorphous metal having a        substantially uniform cross-section;    -   discharging a quantum of electrical energy uniformly through        each of the samples along an electric field axis to uniformly        heat the entirety of said sample to a processing temperature        such that the viscosity of the amorphous material lies between        about 1 Pa-s to about 10⁵ Pa-s;    -   applying a static magnetic field transverse to the electric        field axis to generate an electromagnetic deformational force to        shape the heated sample into an amorphous article; and    -   cooling the article to a temperature below the glass transition        temperature of the amorphous material.

In another embodiment, the invention is directed to an apparatus formagnetic forming for rapidly heating and shaping an amorphous metalincluding:

-   -   a sample of an amorphous metal having a substantially uniform        cross-section;    -   a source of electrical energy;    -   at least two electrodes interconnecting attached to the sample        such that substantially uniform connections are formed between        said electrodes and said sample, wherein the source of        electrical energy is capable of producing a quantum of        electrical energy along an electric field axis sufficient to        uniformly heat the entirety of said sample to a processing        temperature such that the viscosity of the amorphous material        lies between about 1 Pa-s to about 10⁵ Pa-s;    -   a static magnetic field source disposed such that a static        magnetic field is produced transverse to the electric field        axis; and    -   wherein the static magnetic field in association with the        quantum of electric energy is capable of generating an        electromagnetic deformational force sufficient to form or shape        said heated sample to an article.

In still another embodiment, the quantum of electrical energy isdischarged through the electrodes to generate an electrical field alongthe longitudinal length of the sample.

In yet another embodiment, the quantum of electrical energy is at leastabout 100 J and a discharge time constant of between about 10 μs and 10ms.

In still yet another embodiment, the heating and shaping of the sampleare complete in a time of between about 100 μs to 1 s.

In still yet another embodiment, the intensity of the quantum ofelectrical energy is varied during at least one of either the heatingand shaping steps. In such an embodiment, the varying includesgenerating a rapid pre-puke at the sample prior to discharging moreenergy at a slower rate, the energy of said pre-pulse being sufficientto uniformly raise the temperature of the sample to above the glasstransition of the amorphous material, while the energy discharged at aslower rate is sufficient to interact with the magnetic field togenerate an electromagnetic force to sufficiently shape the heatedsample.

In still yet another embodiment, the sample has a shape selected fromthe group consisting of rods, sheets, cylinders, and cubes.

In still yet another embodiment, the magnetic field is disposed inrelation to the electric field axis such that the electromagneticdeformational force is formed normal to the axis of the electric field.

In still yet another embodiment, the source of electrical energy is acapacitor.

In still yet another embodiment, the magnetic field is formed by atleast one magnetic source selected from the group consisting ofpermanent magnets and electromagnets, like for example, Helmholtz coilsor a Helmholtz coil combined with a high permeability soft magneticcore. In one such embodiment, the permanent magnets are selected fromthe group consisting of iron-neodymium-boron magnets and samarium-cobaltmagnets.

In still yet another embodiment, magnetic field is formed from thecombined influence of a plurality of magnetic sources. In one suchembodiment, the plurality of magnetic sources are disposed at differentangles relative to the electric field axis. In another such embodiment,a shaping tool is disposed in proximity to said sample, the shaping toolhaving a three-dimensional mold cavity.

In still yet another embodiment, the apparatus and method includes ashaping tool in proximity to the sample such that the deformationalforce urges the amorphous material into contact with a shaping toolselected from the group consisting of molds, dies, extrusion dies,injection molds, stamps and rollers. In one such embodiment the shapingtool is heated to a temperature preferably around the glass transitiontemperature of the amorphous material. In another such embodiment, theshaping tool is at least partially formed from a magnetic material.

In still yet another embodiment, the shaping tool is a pair of parallelrollers, and wherein the magnetic field is applied normal to the sampleand parallel to a plane defined by the axes of the rollers such thatsaid sample is urged between said rollers to form an amorphous sheetarticle.

In still yet another embodiment, the apparatus includes confining thesample along at least two axes within a channel formed by anon-conducting containment member and discharging the quantum of energyacross the width of the sample such that a deformation force is appliedalong the length of the sample to create a pressure gradient in thesample such that the heated sample is urged along the channel andinjected into a shaping tool In such an embodiment, the shaping tool isone of either a die or a mold.

In still yet another embodiment, the sample contact surfaces between theelectrodes and the sample are flat and parallel.

BRIEF DESCRIPTION OF THE DRAWINGS

The description will be more fully understood with reference to thefollowing figures, which are presented as exemplary embodiments of theinvention and should not be construed as a complete recitation of thescope of the invention, wherein:

FIG. 1 provides a schematic diagram of the layout and geometry of anembodiment of the electromagnetic forming method of the currentinvention;

FIGS. 2A to 2D provides a demonstration of electromagnetic molding inaccordance with the current invention, where (A) provides an image ofthe initial set-up prior to discharge showing a 1 inch wide ribbon,copper electrodes and permanent magnet, (B) provides an image of theapparatus following discharge, (C) provides an image of a sheet formedover a Macor mold in accordance with an exemplary embodiment of thecurrent invention, and (D) provides a series of still images showing theprocess of electromagnetic molding in accordance with the currentinvention;

FIG. 3 provides a schematic of an apparatus for the magnetically drivenrolling of a heated metallic glass plate to form a sheet in accordancewith an embodiment of the invention;

FIG. 4 provides a schematic of an electromagnetic force generated by apermanent magnetic field to carry out injection molding of a confinedcharge into a mold tool in accordance with an embodiment of theinvention;

FIG. 5 provides a schematic of an apparatus geometry appropriate fordischarge heating electromagnetic forces to bond adjacent sheets inaccordance with an embodiment of the invention; and

FIG. 6 provides a schematic data plot of a tailored current profilecomprising two successive pukes of different intensity and duration inaccordance with an embodiment of the invention.

DETAILED DESCRIPTION OF THE INVENTION

The current invention is directed to a method of uniformly heating,rheologically softening, and thermoplastically forming metallic glassesrapidly (typically with processing times of less than 1 second) into anet shape article using an electromagnetic forming force in conjunctionwith Joule heating.

Rapid Capacitor Discharge Forming [RCDF]

The method of the current invention utilizes the discharge of electricalenergy (typically 100 J to 100 KJ) stored in a capacitor to uniformlyand rapidly heat a sample or charge of metallic glass alloy to apredetermined “process temperature” about half-way between the glasstransition temperature of the amorphous material and the equilibriummelting point of the alloy in a time scale of several milliseconds orless in combination with a magnetic forming force, and is referred tohereinafter as magnetically enabled rapid capacitor discharge forming(MERCDF). A conventional RCDF process is described in greater detail inU.S. Pat. Pub. No. US-2009-0236017-A1, the disclosure of which isincorporated herein by reference.

The conventional RCDF process proceeds from the observation thatmetallic glass, by its virtue of being a frozen liquid, has a relativelyhigh electrical resistivity, which can result in high dissipation andefficient, uniform heating of the material at rate such that the sampleis uniformly heated over very short time with the proper application ofan electrical discharge. By rapidly and uniformly heating a BMG, theRCDF method extends the stability of the supercooled liquid againstcrystallization to temperatures substantially higher than the glasstransition temperature, thereby bringing the entire sample volume to astate associated with a processing viscosity that is optimal forforming. The RCDF process also provides access to the entire range ofviscosities offered by the metastable supercooled liquid, as this rangeis no longer limited by the formation of the stable crystalline phase.

In sum, the RCDF process allows for the enhancement of the quality ofparts formed, an increase yield of usable parts, a reduction in materialand processing costs, a widening of the range of usable BMG materials,improved energy efficiency, and lower capital cost of manufacturingmachines. In addition, owing to the instantaneous and uniform heatingthat can be attained in the RCDF method, the thermodynamic and transportproperties throughout the entire range of the liquid metastabilitybecome accessible for measurement.

Magnetic Field Forming

The electromagnetic forming of the current invention is to be contrastedwith conventional electromagnetic forming (EM forming or magneforming).Conventional EM forming is a type of high velocity, cold forming processfor electrically conductive metals, most commonly copper and aluminum.In this process the workpiece is reshaped by high intensity pulsedmagnetic fields that induce a current in the workpiece and acorresponding repulsive magnetic field, rapidly repelling portions ofthe workpiece. During operation, a rapidly changing magnetic fieldinduces a circulating electrical current within a nearby conductorthrough electromagnetic induction. The induced current creates acorresponding magnetic field around the conductor. Because of Lenz'sLaw, the magnetic fields created within the conductor and work coilstrongly repel each other. The high work coil current (typically tens orhundreds of thousands of amperes) creates an ultrastrong magnetic forcethat overcomes the room-temperature yield strength of the metal workpiece, causing permanent deformation. However, this process requiresthat the metal be shaped in a cool state.

As discussed, the current invention provides a method of formingmetallic glass, sheets, tubes, or rods, which utilizes a metallic glasscharge in the form of a sheet, tube, or rod of essentially uniform crosssection. During the process, a large current puke generated by thedischarge of a capacitor bank through the length of the sample is usedto rapidly and uniformly heat the sample to a target temperature in thesupercooled liquid region. Following heating, the heated sample issubjected to an electromagnetic force generated by the interaction ofthe applied current with a magnetic field oriented normally to thedirection of current flow.

FIG. 1, below, shows a schematic illustration of an exemplary geometryused in implementing the invention. In the example geometry used forillustration, the sample (10), which is disposed in a position adjacentto a shaping element (12), such as a mold, injection molding port,roller sheet, etc., is heated by the application of an appliedelectrical current (I) across the sample. The heated sample is thensubjected to an electromagnetic force (F) formed by the applied current(I) of the inductive heating and the transverse magnetic field (B),which in this example is normal to the current. The sample is molded bythe resulting electromagnetic force, because the heated sample is aviscous liquid, which deforms under the influence of the electromagneticforce to replicate the shape defined by the shaping element (in theexample in FIG. 1, a mold).

It is observed that most metallic glasses are non-magnetic, especiallyabove their glass transition, and therefore it is not obvious that anelectromagnetic forming process would operate on them. However, theelectromagnetic forming works in these amorphous systems because themetallic glass is simultaneously being heated by generating an electricfield across it while present in a transverse magnetic field.

Below is a list of the basic elements that allow for the combined use ofcapacitive discharges and magnetic fields to carry-out processing andnet shape forming of metallic glass materials. To one skilled in theart, it should be apparent that numerous variations are possible withinthe basic invention, however, for the purposes of disclosure, theinvention can be defined and characterized by the following basicelements:

(1) The Sample

A metallic glass charge having an essentially uniform cross section.Although a uniform cross-section is required, it should be understoodthat any shape with uniform cross section may be used, such as, forexample, rods, sheets, cylinders, cubes, etc. Likewise, any metallicglass having an accessible amorphous phase may be used, such as, forexample, metallic glasses disclosed in U.S. Pat. Nos. 5,288,344;5,368,659; 5,618,359; and 5,735,975, the disclosures of each of whichare incorporated herein by reference.

(2) The Electrical Circuit

An electrical capacitor which is used to store and discharge electricalenergy by uniform Ohmic dissipation with an electrical current along thelength of the sample thereby uniformly heating the sample to a liquidprocessing temperature above the glass transition temperature of themetallic glass in accordance with U.S. Pat. Pub. No. US-2009-0236017-A1,the disclosure of which is incorporated herein by reference.

(3) The Processing Temperature

A processing temperature chosen to be in a range whereby the viscosityof the glass forming liquid lies between about 1 Pas-s to about 10⁵Pas-s. It will be understood that methods of determining the temperaturenecessary to bring any metallic glass within this viscosity range arewell-known by those skilled in the art.

(4) The Nature of the Magnetic Field

A static magnetic field applied in the region surrounding the samplethat reacts with the time and space dependent current flowing in thesample to produce electromagnetic forces that act on the sample to shapeand form the liquid sample into a desired shape. The shaping and formingcan be carried out with or without the use of an auxiliary shaping tool,such as, for example, a mold, die, sheet roller, extruder, etc. (Severalexamples of different shaping took incorporated with the magnetic fieldshaping process of the current invention are shown in Examples 1 to 6,below.)

(5) The Geometry of the Magnetic Field

Although the magnetic field is static, it may generally vary in space insuch a manner as to control the distribution of electromagnetic shapingforces over the sample to produce optimum forming of a net-shape. Inparticular, although in the basic example provided in FIG. 1, above, thegeometry of the magnetic field in relation to the applied current ischosen so that the electromagnetic force applied to the sample isdirected normal to the sample and against a die tool or into a moldtool, it should be understood that the force applied to the sample isproportional to the angle of the current and magnetic field inaccordance with the Lorentz force equation (F=I×B·sin Θ). The forcepushes against the sample normal to the sample. Accordingly, themagnetic field and electric current can be positioned in relation toeach other in any geometry suitable for applying the necessary shapingforce to the sample. For example, the field may be produced by a singleor multiple permanent magnets arranged in a configuration to produce adesired distribution of forces over the sample. The static magneticfield may also be created all in part by electromagnets. Theelectromagnets may be used in concert with one or more permanentmagnets. The permanent magnets may be of the“Iron-Neodymium-Boron”-type, “Samarium-Cobalt type”, or and other commontype of permanent magnet. Alternatively, the mold itself could also befabricated from a magnetic material.

(6) Quenching

Following shaping, the final part is cooled below the glass transitiontemperature of the metallic glass in a sufficiently short time to avoidsubstantial crystallization of the part. The final component producedthereby remains in a substantially glassy state. For purposes ofdefinition, the final part should comprise at least 50% metallic glassand less than 50% of any crystallized material. Cooling can beaccomplished by any reasonable means, including, for example, thermalconduction to the mold tool, or by conduction, convection, or radiationto the ambient environment surrounding the final net shaped component.

Although one basic embodiment of the MERCDF method of the currentinvention is described above, as are the basic elements required forusing a magnetic field to create electromagnetic “forming” forces in acurrent carrying metallic glass work piece, it should be understood thatthe method can be extended to various other geometries and to otherforming methods. For example, multiple permanent magnets with high fieldstrength such as Iron Neodymium Born permanent magnets can be use toproduce spatially non-uniform permanent fields which interact with thesample current to produce a desired distribution of forming forces onthe work-piece. This force distribution acting on the work-piece can betailored to optimize the net shaping capability of the invention. Inaddition, since magnetic forces scale with current while heatdissipation in the charge scales quadratically with current, one canalso use discharges from multiple capacitors to separately controlsample heating and shaping. These variations and others, will bedescribed more thoroughly in the exemplary embodiments presented below.

EXEMPLARY EMBODIMENTS

As examples of the invention that embody the above basic elements, thefollowing exemplary cases of net shape forming from various initialshapes to final useful parts are provided. The examples given here areintended to illustrate several useful variants of the basic invention.All these variants are based on the basic elements of the invention asoutlined at the beginning of this section. These variants should all beconsidered as alternative embodiments of the invention as disclosed inthe present document. The invention has many other possible variantswhich can be implemented by someone skilled in the art using modifiedgeometries as required to produce a suitable arrangement ofelectromagnetic forces on a capacitive discharge heated work-piece.

Example 1 Molding

As a demonstration of the method in a simple molding case, a thin sheetof metallic glass (Metglas MBF 50—Ni-based brazing alloy) produced byplanar flow casting is used. The sheet is in the form of a ribbon ofwidth 1-2″, thickness of about 30-40 μm. Such ribbons are commerciallyavailable in long lengths from the Metglas Division of Hitachi Metals. A0.262 Farad capacitor band controlled by a silicon rectifier was used. Asimple demonstration die tool was fabricated from a machinable ceramic,Macor. For demonstration, a Macor die of circular symmetry withconcentric grooves machined in the surface was chosen as shown in FIGS.2A to D.

A reasonably homogeneous magnetic field of ˜1 kG was applied in theregion surrounding the mold and was provided by a permanent magnet asseen in FIGS. 2A and 2B. The capacitor was charged to voltages in therange of 20-40 volts and discharged through copper leads and a copperclamping strip on the ribbon. FIG. 2A shows the original ribbon in themagnetic field prior to discharge. FIG. 2B shows the ribbon as heated inthe magnetic field by the capacitive discharge to a process temperatureof ˜700 C. FIG. 2C shows the shaped ribbon after a total elapsed time ofseveral seconds.

A high speed video movie taken at 1000 frames/s shows that the sample isheated to the process temperature in several milliseconds, formed bydynamic deformation on the mold within about 10 milliseconds followingheating, and cooled to ambient temperature after 1-2 seconds totalelapsed time. The result, which is shown in a series of stills in FIG.2D demonstrates a “proof of concept” of the use of an electromagneticforce generated by the interaction of the sample current with apermanent magnetic field to “compressively” forge a sheet into a shapedpart.

Example 2 Sheet Forming

FIG. 3 shows an exemplary set-up for a method of forming sheets from aplate using twin rolls. As shown, in this embodiment an electromagneticforce (F) is exerted on a square or rectangular bar (14) of metallicglass located above the gap between two rotating rollers (16). Theelectrical discharge (I) is transferred to the sample by electrodes (notshown), which contact the ends of the bar (14). Current is induced alongthe length of the bar. A static magnetic field (B) is applied normal tothe bar (14) and parallel to the plane defined by the two axes (18) ofthe twin rollers (16). The electromagnetic force drives the heated barinto the gap between the rollers to produce a rolled sheet. The bar maybe contained in a vertical channel (not shown) made of electricallynon-conducting material in order to confine and efficiently guide thematerial through the rollers.

Example 3 Injection Molding & Extrusion of a Net-Shaped Component

In another embodiment, the basic method may be used to injection mold asquare rod into a mold cavity of net-shape. As shown in FIG. 4, in thisembodiment an electromagnetic force (F) can be used to create a pressuregradient along the length of a metallic glass sample (20) duringdischarge heating of the rod by a current (I) across its width providedby two bar shaped electrodes (22). To prevent leakage, the charge isconfined by non-conducting containment walls (24). A mold tool withsuitable gating and mold cavity can be provided (not shown) that wouldthen be filled by the injected liquid as it is heated to a suitableprocess temperature (as described above).

Alternatively, the same set-up can be used for a method of extrusion ofa net-shaped component of uniform cross-section using an extrusion die.In this embodiment, the apparatus is used to force a heated charge ofmetallic glass through an extrusion die. In this case, the die would belocated at the location of the mold in FIG. 4.

Example 4 Multiple Magnet Forming

In another embodiment, multiple magnets may be used to form a sheet intothe form of a box-shaped “case” in the form of a rectangular solidhaving width and length larger than depth. As described above, it willbe understood that a suitable configuration of multiple permanentmagnets can be used to generate a distribution of forces on awork-piece, which can be tailored to shape the piece into a mold cavityof three dimensional shape such as a box shaped, ring shaped, sphericalshaped, or other desired shape.

Example 5 Joining and Bonding of Components

Two components (sheets, bars, plates) may be heated by a capacitivedischarge, simultaneously using the method of the current invention. Ifthe direction of current flow in the two components is reversed, thenthe electromagnetic force can be used to drive the two components intocontact. An example of this geometry is illustrated in FIG. 5. As shown,when the two strips (26) are heated by capacitive discharges (I) thathave opposite current flow to an appropriate process temperature, anelectromagnetic force (F) is uniformly exerted over the two surfaces,the two pieces may be driven together and joined or bonded.

After joining, the pieces may be quenched below the glass transitiontemperature using any suitable method, such as via conduction orconvection to a suitable fluid, or via radiation to the surroundings.For example, in one embodiment the outer surfaces of the pieces could beexposed to a stream or reservoir of a gas or liquid, such as, forexample, helium gas or a suitable oil bath.

Example 6 Current Profile Shaping

Because heating and forming are essentially coupled in the presentmethod, the profile of the current may be tailored such that the heatingand forming stages are effectively decoupled. In one embodiment forexample, it is preferable to first apply a high intensity short durationcurrent pulse first, followed by a second low intensity long durationpuke. As the rate of heating is related quadratically to the current(˜I²) while the force is related linearly to current (˜I), the vastmajority of the heating will take place during the first high-intensityshort-duration current puke, while the vast majority of forming willtake place during the second low-intensity long-duration current puke.Specifically, the first puke will be utilized to rapidly and uniformlyraise the sample temperature to above the glass-transition temperatureat which point the viscosity of the sample begins to drop. Even thoughthe high current of the first puke will induce a high force, this forcewill not produce substantial forming because the sample viscosity willbe fairly high for the majority of the duration of the first puke. Thesecond pulse with much lower intensity but much longer duration willresult in only slightly further heating compared to the first puke,because heating is proportional to ˜I². As force is proportional to ˜I,however, the second pulse will induce a force not much smaller than thatin the first puke, applied over a much longer time during which thesample viscosity is much lower, thereby contributing to much moreforming. This embodiment is demonstrated graphically in FIG. 6.

In the embodiment described above, the magnetic field could be inducedby electronically activating an electromagnet, like for example, aHelmholtz coil, in synchrony with the discharge of the additionalquantum of energy. As such, heating and forming are more effectivelydecoupled, as no force will be induced during the first current pukesuch that it is utilized solely for heating.

DOCTRINE OF EQUIVALENTS

Those skilled in the art will appreciate that the foregoing examples anddescriptions of various preferred embodiments of the present inventionare merely illustrative of the invention as a whole, and that variationsin the steps and various components of the present invention may be madewithin the spirit and scope of the invention. For example, it will beclear to one skilled in the art that additional processing steps oralternative configurations would not affect the improved properties ofthe method/apparatus of the current invention nor render themethod/apparatus unsuitable for its intended purpose. Accordingly, thepresent invention is not limited to the specific embodiments describedherein but, rather, is defined by the scope of the appended claims.

What is claimed is:
 1. A method of rapidly heating and shaping anamorphous metal using electrical energy discharge in the presence of amagnetic field generating an electromagnetic force comprising: providingat least one sample of amorphous metal, said sample having asubstantially uniform cross-section; discharging a quantum of electricalenergy uniformly through each of said at least one samples along anelectric field axis to uniformly heat the entirety of said sample to aprocessing temperature such that the viscosity of the amorphous metallies between about 1 Pa-s to about 10⁵ Pa-s; applying a static magneticfield transverse to the electric field axis to generate anelectromagnetic deformational force to shape the heated sample; andcooling said article to a temperature below the glass transitiontemperature of the amorphous metal to produce an amorphous article. 2.The method of claim 1, wherein the step of discharging said quantum ofelectrical energy occurs through at least two electrodes connected toopposite ends of each of said at least one samples and generates anelectrical field along the longitudinal length of said sample.
 3. Themethod of claim 1, wherein the quantum of electrical energy is deliveredby discharging a capacitor.
 4. The method of claim 1, wherein thequantum of electrical energy is at least about 100 Joules and adischarge time constant of between about 10 μs and 10 ms.
 5. The methodof claim 1, wherein the heating and shaping of the sample are completein a time of between about 100 μs to 1 s.
 6. The method of claim 1,further comprising varying the intensity of the quantum of electricalenergy during at least one of either the heating and shaping steps. 7.The method of claim 6, wherein the step of varying includes generating apre-puke at the sample prior to discharging an additional quantum ofenergy at a first rate; the energy of said pre-puke being sufficient toraise the temperature of the sample at the interface to above the glasstransition of the amorphous metal; and the additional quantum of energybeing discharged at a rate slower than the rate of said pre-puke with anenergy sufficient to interact with the magnetic field to generate anelectromagnetic force sufficient to shape the heated sample.
 8. Themethod of claim 7, wherein the magnetic field is induced by activatingan electromagnet in synchrony with the discharge of the additionalquantum of energy.
 9. The method of claim 1, wherein the sample has ashape selected from the group consisting of rods, sheets, cylinders, andcubes.
 10. The method of claim 1, wherein the magnetic field is disposedin relation to the electric field axis such that the electromagneticdeformational force is formed normal to the axis of the electric field.11. The method of claim 1, wherein the magnetic field is formed by atleast one magnetic source selected from the group consisting ofpermanent magnets and electromagnets.
 12. The method of claim 11,wherein the permanent magnets are selected from the group consisting ofiron-neodymium-boron magnets and samarium-cobalt magnets.
 13. The methodof claim 1, wherein the magnetic field is formed from the combinedinfluence of a plurality of magnetic sources.
 14. The method of claim13, wherein the plurality of magnetic sources are disposed at differentangles relative to the electric field axis.
 15. The method of claim 13,further comprising providing a shaping tool in proximity to said sample,the shaping tool having a three-dimensional mold cavity.
 16. The methodof claim 1 further comprising providing a shaping tool in proximity tosaid sample such that the deformational force urges the heated amorphousmetal into contact with a shaping tool selected from the groupconsisting of molds, dies, extrusion dies, injection molds, stamps androllers.
 17. The method of claim 16, wherein the shaping tool is heatedto a temperature preferably around the glass transition temperature ofthe amorphous metal.
 18. The method of claim 16, wherein the shapingtool is at least partially formed from a magnetic material.
 19. Themethod of claim 16, wherein the shaping tool is a pair of parallelrollers, and wherein the magnetic field is applied normal to the sampleand parallel to a plane defined by the axes of the rollers such thatsaid sample is urged between said rollers to form an amorphous sheetarticle.
 20. The method of claim 16, further comprising providing anelongated sample; confining the sample along at least two axes within achannel formed by a non-conducting containment member; discharging thequantum of energy across the width of the sample; and applying adeformation force along the length of the sample to create a pressuregradient in the sample such that the heated sample is urged along thechannel and injected into a shaping tool.
 21. The method of claim 20,wherein the shaping tool is one of either a die or a mold.
 22. Amagnetic forming apparatus for rapidly heating and shaping an amorphousmetal using electrical energy discharge in the presence of a magneticfield generating an electromagnetic force comprising: a sample of anamorphous metal, said sample having a substantially uniformcross-section; a source of electrical energy; at least two electrodesinterconnecting said source of electrical energy to said sample ofamorphous metal, said electrodes being attached to said sample such thatsubstantially uniform connections are formed between said electrodes andsaid sample, wherein said source of electrical energy is capable ofproducing a quantum of electrical energy along an electric field axissufficient to uniformly heat the entirety of said sample to a processingtemperature such that the viscosity of the amorphous metal lies betweenabout 1 Pa-s to about 10⁵ Pa-s; a static magnetic field source disposedsuch that a static magnetic field is produced transverse to the electricfield axis; and wherein said static magnetic field in association withsaid quantum of electric energy is capable of generating anelectromagnetic deformational force sufficient to form said heatedsample to a shaped article.
 23. The apparatus of claim 22, wherein thesample contact surfaces are flat and parallel.
 24. The apparatus ofclaim 22, wherein the at least two electrodes are connected to oppositeends of each of said at least one samples and generates an electricalfield along the longitudinal length of said sample.
 25. The apparatus ofclaim 22, wherein the quantum of electrical energy is delivered bydischarging a capacitor.
 26. The apparatus of claim 22, wherein thequantum of electrical energy is at least about 100 J and a dischargetime constant of between about 10 μs and 10 ms.
 27. The apparatus ofclaim 22, wherein the heating and shaping of the sample are complete ina time of between about 100 μs to 1 s.
 28. The apparatus of claim 22,further comprises a controller in signal communication with said sourceof electrical energy, the controller capable of varying the intensity ofthe quantum of electrical energy during at least one of either theheating and shaping steps.
 29. The apparatus of claim 28, wherein thecontroller is capable of generating a pre-pulse at the sample prior todischarging an additional quantum of energy at a first rate; the energyof said pre-pulse being sufficient to raise the temperature of thesample at the interface to above the glass transition of the amorphousmetal; and the additional quantum of energy being discharged at a rateslower than the rate of said pre-pulse with an energy sufficient tointeract with the magnetic field to generate an electromagnetic forcesufficient to shape the heated sample.
 30. The apparatus of claim 29,wherein the magnetic field is induced by activating an electromagnet insynchrony with the discharge of the additional quantum of energy. 31.The apparatus of claim 22, wherein the sample has a shape selected fromthe group consisting of rods, sheets, cylinders, and cubes.
 32. Theapparatus of claim 22, wherein the magnetic field is disposed inrelation to the electric field axis such that the electromagneticdeformational force is formed normal to the axis of the electric field.33. The apparatus of claim 22, wherein the magnetic field is formed byat least one magnetic source selected from the group consisting ofpermanent magnets and electromagnets.
 34. The apparatus of claim 33,wherein the permanent magnets are selected from the group consisting ofiron-neodymium-boron magnets and samarium-cobalt magnets.
 35. Theapparatus of claim 22, wherein the magnetic field is formed from thecombined influence of a plurality of magnetic sources.
 36. The apparatusof claim 35, wherein the plurality of magnetic sources are disposed atdifferent angles relative to the electric field axis.
 37. The apparatusof claim 35, further comprising a shaping tool in proximity to saidsample such that the electromagnetic deformational force urges theamorphous metal into contact with the shaping tool, the shaping toolhaving a three-dimensional mold cavity.
 38. The apparatus of claim 22,further comprising a shaping tool in proximity to said sample such thatthe deformational force urges the amorphous metal into contact with theshaping tool, wherein the shaping tool is selected from the groupconsisting of molds, dies, extrusion dies, injection molds, stamps androllers.
 39. The apparatus of claim 38, wherein the shaping tool isheated to a temperature preferably around the glass transitiontemperature of the amorphous metal.
 40. The apparatus of claim 38,wherein the shaping tool is at least partially formed from a magneticmaterial.
 41. The apparatus of claim 38, wherein the shaping tool is apair of parallel rollers, and wherein the magnetic field is appliednormal to the sample and parallel to a plane defined by the axes of therollers such that said sample is urged between said rollers to form anamorphous sheet article.
 42. The apparatus of claim 38, furthercomprising a non-conducting containment channel into which the sample ispositioned, the containment channel confining the sample along at leasttwo axes; and wherein the source of electric energy is disposed suchthat the quantum of energy is discharged across the width of the sample,and the magnetic field source is disposed such that the electromagneticdeformation force is applied along the length of the sample to create apressure gradient in the sample such that the heated sample is urgedalong the channel and injected into a shaping tool.
 43. The apparatus ofclaim 42, wherein the shaping tool is one of either a die or a mold.